TWI CSWIP 3.1 Wis 5 Welding Inspection NDT: World Centre For Materials Joining Technology

TWI CSWIP 3.
1 WIS 5 WELDING INSPECTION NDT
Copyright 2004, TWI Ltd
World Centre for Materials Joining Technology
What is NDT?
A method of determining:
the integrity of a material, component or structure the characteristic of an object
Without doing harm!
NDT methods
Visual Inspection Penetrant Inspection Magnetic Particle Inspection Eddy Current Inspection Ultrasonic Inspection Radiographic Inspection
Uses of NDT methods?

Flaw Detection and Evaluation
Dimensional Measurements
Structure and Microstructure Characterization Estimation of Mechanical and Physical Properties Material Sorting and Chemical Composition Determination
Certification systems
BS EN 473 (ISO 9712) PCN ASNT CSWIP In House
Welding gauge
Visual inspection of welds using the multi-purpose welding gauge
Using the welding gauge

Angle of preparation (from 0 to 60 in 5 increments)
Linear Misalignment
Using the welding gauge

Excess weld metal/root penetration
Undercut / mechanical damage (grinding etc)
Using welding gauge

Fillet weld actual throat thickness (up to 20 mm or 3/4 inch)
Fillet weld leg length (up to 25 mm)

Other gauges for weld inspection
Tapered gauge
Hi-Lo gauge
Liquid penetrant inspection

Dye Penetrant Inspection (DPI) Penetrant Flaw Detection (PFD) Penetrant testing (PT) Surface inspection method Applicable to all non-porous, non-absorbing materials

Penetrating fluid applied to component and drawn into defect by capillary action Penetrating fluid removed from component surface (but not from defect)
Principle of capillary action

Interaction of adhesive and cohesive forces

Penetrating fluid applied to component and drawn into defect by capillary action Developer applied to surface

Penetrating fluid applied to component and drawn into defect by capillary action Developer applied to surface
Penetrant drawn back out of the defect by reverse capillary action
System classification
PENETRANT REMOVAL Solvent Water washable Post emulsifiable DEVELOPERS
Colour contrast Fluorescent Dual
Dry powder Aqueous Non-aqueous
Advantages of LPI
Applicable to non-ferromagnetic materials Able to test large parts with a portable kit Batch testing Applicable to small parts with complex geometry Simple,cheap easy to interpret Sensitivity
Disadvantages of LPI
Will only detect defects open to the surface Careful surface preparation required Not applicable to porous materials Temperature dependant Cannot retest indefinitely Compatibility of chemicals
Magnetic Particle Inspection

Test method for the detection of surface and sub-surface indications in ferromagnetic materials Magnetic field induced in component Defects disrupt the magnetic flux Defects revealed by applying ferromagnetic particles
Principle of MPI : Flux leakage

No Defect Defect
Lines of flux follow the path of least resistance

MPI equipment
Magnetic particle inspection
Advantages of MPI
Will detect some sub-surface defects Rapid and simple to understand Pre-cleaning not as critical as with DPI Will work through thin coatings Cheap rugged equipment Direct test method
Disadvantages of MPI
Ferromagnetic materials only Requirement to test in 2 directions Demagnetisation may be required Odd shaped parts difficult to test Not suited to batch testing Can damage the component under test
Eddy Current Inspection

An alternating current is passed through a coil

A.C. generates an alternating field


Alternating field generates eddy currents in conductive materials


Alternating field generates eddy currents in conductive materials Eddy currents generate opposing field which modifies current in coil

The size of the electrical currents induced in metals by alternating magnetic fields is affected by: Electrical conductivity Stand off distance
Flaws
Permeability Specimen dimensions
Advantages of ECI
Sensitive to surface defects Can detect through several layers Can detect through surface coatings Accurate conductivity measurements Can be automated Little pre-cleaning required Portability
Disadvantages of ECI
Very susceptible to permeability changes Only on conductive materials Will not detect defects parallel to surface Not suitable for large areas and/or complex geometry's Signal interpretation required No permanent record (unless automated)
Ultrasonic Inspection
Principle
High frequency sound sound waves are introduced into a material Interfaces between materials of differing acoustic properties reflect or transmit sound Reflected sound is displayed on a CRT
Ultrasonic inspection equipment
Ultrasonic inspection equipment
0 degree probe
Angle probe
Defect orientation
0 degree Probes
Screen
Depth
Metal
Depth
Defect orientation
Angle probes
Screen
Range
Range Depth = Range x Cos (Probe angle)

Advantages of UI
Sensitive to cracks at various orientations Portability Safety Able to penetrate thick sections Measures depth and through wall extent
Disadvantages of UI
No permanent record (unless automated) Not easily applied to complex geometries and rough surfaces. Unsuited to course grained materials Requires highly skilled and experienced technicians
Radiographic inspection
Electromagnetic radiation is imposed upon a test object Radiation is transmitted to varying degrees dependant upon the density of the material through which it is travelling Variations in transmission detected by photographic film or fluorescent screens Applicable to metals,non-metals and composites
Radiographic Inspection
Radiation source
Lower density
Higher density
Specimen Film
Radiographic image
Radiographic equipment
Advantages of Radiography
Permanent record Internal flaws Can be used on most materials Direct image of flaws Real - time imaging
Disadvantages of Radiography
Health hazard Sensitive to defect orientation Limited ability to detect fine cracks Access to both sides required Limited by material thickness Skilled interpretation required Relatively slow High capital outlay and running costs

TWI CSWIP 3.1 Wis 5 Welding Inspection NDT: World Centre For Materials Joining Technology

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TWI CSWIP 3.

1 WIS 5 WELDING INSPECTION NDT

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

the integrity of a material, component or structure the characteristic of an object

Without doing harm!

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Uses of NDT methods?

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Using the welding gauge

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Using the welding gauge

Undercut / mechanical damage (grinding etc)

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Using welding gauge

Fillet weld leg length (up to 25 mm)

World Centre for Materials Joining Technology

Other gauges for weld inspection

World Centre for Materials Joining Technology

Liquid penetrant inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Liquid penetrant inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Principle of capillary action

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Liquid penetrant inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Liquid penetrant inspection

Penetrant drawn back out of the defect by reverse capillary action

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Liquid penetrant inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Liquid penetrant inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Colour contrast Fluorescent Dual

Dry powder Aqueous Non-aqueous

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Magnetic Particle Inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology